Double envelope for standard production printing

ABSTRACT

A method and apparatus includes/uses a media supply that maintains the media sheets and a printing engine that places markings on the sheets. The media sheets have multiple opposing partially formed envelopes. The markings placed have opposite orientations on the opposing envelopes. The apparatus also optionally includes a separator that separates the opposing partially formed envelopes after the printing engine places the marking, to leave partially formed individual envelopes. A folder device optionally folds the partially formed individual envelopes to produce completed individual envelopes.

BACKGROUND SUMMARY

Embodiments herein generally relate to electrostatographic printers andcopiers or reproduction machines, and more particularly, concern asystem and method of printing small envelopes, and more particularly, tosystems and methods that use media sheets that have multiple opposingpartially formed envelopes.

Many companies are interested in providing customers with standard, lowcost small envelopes (such as #10 envelopes) that can be easilyprocessed through existing printing production products. Standard “offthe shelf” #10 envelopes are only 4.125″ long. Standard nip spacing in apaper path of a printing device can be about 165 mm long (6.5″).Transporting such small envelopes through a paper path would requiremuch closer nip spacing than the current standard nip spacing resultingin increased cost, power, and noise if printing products weremanufactured to have smaller nip spacing. Feeding and stacking designwould also see significant impacts in cost, power, and noise if theywere redesigned to handle small envelopes, since they are not currentlydesigned to feed or stack papers of such a small size.

Therefore, the following disclosure presents a system and method thatutilizes a sheet that has a “double envelope” which is intended to bedie cut and folded to produce pairs of individual envelopes having thesame dimensions as a standard #10 envelope. As explained in greaterdetail below, with embodiments herein, the two envelopes are joinedtogether along the top edge of the envelope flap. Before being separatedfrom one another, the pairs of envelopes are mirror images of eachother. Therefore, the printing process prints addresses and/or otherinformation in a proper orientation for each individual envelope (thatare upside down with respect to one another) since the envelopes faceopposite each other. After printing, the envelopes are separated (diecut) to leave two separate envelopes.

Embodiments herein include a method of printing small envelopes, such as#10 envelopes. The method supplies media sheets that have multipleopposing partially formed envelopes using a roller nip based sheetfeeding system. If the individual envelopes were fed into the sheetfeeding system, they would be too small because the sheet feeding systemhas nip spacing larger than the individual envelopes. Therefore,embodiments herein use media sheets that are large enough for the nipspacing, and that have such multiple opposing partially formedenvelopes.

Once the sheets are supplied, the method places markings on the sheetsof the opposing partially formed envelopes. Because the partially formedenvelopes oppose one another, the markings have opposite orientations.Saying the markings have “opposite orientations” means that the markingshave a first orientation and a second orientation that is upside downwith respect to the first orientation.

After printing, the method separates the opposing partially formedenvelopes to leave partially formed individual envelopes. The mediasheets have a separating line between pairs of the opposing partiallyformed envelopes and the method separates the media sheets along theseparating line. The partially formed individual envelopes are thenfolded to produce completed individual envelopes. Also, the foldingprocess folds a panel of the partially formed individual envelopesbordering the separating line toward the center of the partially formedindividual envelopes to put the envelopes in final form (completedindividual envelopes).

This disclosure also presents apparatus embodiments that include a mediasupply that maintains the media sheets and a printing engine that placesmarkings on the sheets. Again, such markings have opposite orientationson the opposing envelopes of the sheets. The apparatus also includes aseparator (cutter or dicer) that separates the opposing partially formedenvelopes after the printing engine places the marking, to leavepartially formed individual envelopes. The separator divides the mediasheets along the separating line.

A folding device (folder) folds the partially formed individualenvelopes to produce the completed individual envelopes. The folderdevice folds a panel of the partially formed individual envelopesbordering the separating line toward the center of the partially formedindividual envelopes to put the envelopes in final form (completedindividual envelopes).

A roller nip based sheet feeding system provides a sheet path betweenthe media supply, the printing engine, the separator, and the folder.Again, the sheet feeding system has nip spacing larger than the size ofthe individual envelopes. Therefore, embodiments herein use media sheetsthat are large enough for the nip spacing, and that have such multipleopposing partially formed envelopes.

These and other features are described in, or are apparent from, thefollowing detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

Various exemplary embodiments of the systems and methods are describedin detail below, with reference to the attached drawing figures, inwhich:

FIG. 1 is a flowchart illustrating method embodiments herein;

FIG. 2 is a top-view schematic diagram of a multi-envelope sheetaccording to embodiments herein;

FIG. 3 is a top-view schematic diagram of a multi-envelope sheetseparated into individual envelopes according to embodiments herein;

FIG. 4 is a top-view schematic diagram of a multi-envelope sheetseparated into individual envelopes according to embodiments herein;

FIG. 5 is a top-view schematic diagram of a multi-envelope sheetaccording to embodiments herein;

FIG. 6 is a top-view schematic diagram of a multi-envelope sheet havingprint markings according to embodiments herein; and

FIG. 7 is a schematic diagram of system embodiments herein.

DETAILED DESCRIPTION

As mentioned above, many companies are interested in providing customerswith standard, low cost small envelopes that can be easily processedthrough existing printing production products. However, transportingsuch small envelopes through a paper path would require much closer nipspacing than the current standard nip spacing resulting in increasedcost, power, and noise if printing products were manufactured to havesmaller nip spacing. Feeding and stacking design would also seesignificant impacts in cost, power, and noise if they were redesigned tohandle small envelopes.

Therefore, as shown in flowchart form in FIG. 1, the method works with aprinting system in items 100-102 and works with inline or offlinefinishing in items 104-110. The method supplies media sheets that havemultiple opposing partially formed envelopes using a roller nip basedsheet feeding system in item 100. Embodiments herein print on smallenvelopes, such as #10 envelopes (or any sized envelope such as a #1,#2, #3 . . . #99, etc. size envelope). While one specific envelope size(e.g., #10 envelopes) is mentioned herein, those ordinarily skilled inthe art would understand that the embodiments herein are applicable toany appropriately sized envelope that is too small for the equipment(sheet feeding trays, nip rollers, finishing units, etc.) on which suchenvelopes will be printed. Therefore, the embodiments herein are notlimited to the specific envelope sizes that are discussed herein and areuseful with all different sized and shaped envelopes.

Thus, one feature of the embodiments herein is that they are useful withenvelopes of any size and shape that are too small for the processingequipment to which they are being supplied. If the individual envelopeswere fed into the sheet feeding system, they would be too small becausethe sheet feeding system has nip spacing larger than the individualenvelopes. Therefore, embodiments herein use media sheets that are largeenough for the nip spacing, and that have such multiple opposingpartially formed envelopes.

More specifically, referring to FIG. 2, one exemplary media sheet 200 isillustrated that includes two separate envelopes 220, 222. Each of theenvelopes includes side flaps 202 and a bottom flap 204. Item 206represents a fold line, item 208 represents a separation line, and item210 represents some form of adhesive or bonding structure(moisture-activated adhesive, peel back self-adhesive, physicalclipping/hooking structures, etc.). The fold line 206 and separationline 208 are not actual printed lines, but instead represent locationswhere folds and cuts will be made, as shown in greater detail below.

The sheet designs shown in FIGS. 2-6 were not generally known before thepresent invention; however the methods and materials used to create suchmulti-envelope sheets are well known to those ordinarily skilled in theart. To create such multi-envelope sheets, sheets of paper are cut,folded, and glued to create the opposing partially formed envelopes thatare illustrated in FIGS. 2-6. While the embodiments herein are notlimited to the specific design shown in FIGS. 2-6, such sheets could beformed by cutting a sheet of paper to include the side flaps 202 and thebottom flaps 204. The side flaps 202 could then be folded inward, thebottom flaps 204 could be folded inward, and the bottom flaps 204 couldbe adhered (glued, bonded, etc.) to the side flaps 202.

The details regarding different ways to make envelopes, different typesof folds, different types of paper cutters, different types ofadhesives, etc. are well known to those ordinarily skilled in the art isshown for example by U.S. Pat. Nos. 6,845,864; 5,887,780; 5,050,812;4,807,805; 4,071,997; and 761,912 (the complete disclosures of which areincorporated herein by reference) and such structures and processes arenot discussed in detail herein.

Once the sheets are supplied in item 100 (FIG. 1), the method placesmarkings on the sheets of the opposing partially formed envelopes initem 102. For example, FIG. 6 illustrates the opposite side of the sheet200 shown in FIG. 2. The printing process in item 102 prints mailingaddresses 602 and return addresses 604 of the opposite side of the sheet200. Because the partially formed envelopes oppose one another, themarkings 602, 604 placed in item 102 have opposite orientations, asshown in FIG. 6. Saying the markings have “opposite orientations” meansthat the markings have a first orientation (right side of FIG. 6) and asecond orientation (left side of FIG. 6) that is upside down withrespect to the first orientation.

After printing in item 102, the method separates the opposing partiallyformed envelopes in item 104 to leave partially formed individualenvelopes shown by item 106. It is also possible that the printer mayonly print the double envelopes and that separation, folding, stuffing,and gluing may be done offline. This is also shown in FIG. 3 where, asdiscussed above, the method separates the media sheet 200 into twoindividual partially formed envelopes 300, 302 along the separating line208.

The partially formed individual envelopes are then folded in item 108 toproduce completed individual envelopes shown by item 110. As shown inFIGS. 3 and 4, this folding process 108 folds a panel 304 of thepartially formed individual envelopes 300, 302 bordering the separatingline 208 (FIG. 2) toward the center of the partially formed individualenvelopes 300, 302 (as shown by the arching arrows in FIG. 3) to put theenvelopes 300, 302 in final form (completed individual envelopes) asshown in FIG. 4. Therefore, the folding process in item 108 folds thetop flaps 304 away from the separating line 208 and toward the center ofeach individual envelope 300, 302.

The flaps 304 are shown in their folded over position in FIG. 4;however, the adhesive 210 is not activated (is not moistened, is notexposed, etc.) so that the flaps 304 are only folded over, and are notbonded to the remaining flaps 202, 204 (until the adhesive 210 isactivated by the user). Therefore, after the folding process in item108, the user can still access the pocket created by flaps 202 and 204which allows the user to insert a letter or other item into the envelopebefore activating the adhesive 210 and sealing the envelope.

While dual envelope sheets 200 are discussed in the previous example,the embodiments herein can include any even number of envelopesdepending upon the size of the envelope and the size of the sheet 200.For example, as shown in FIG. 5, the sheet 500 includes two pairs ofopposing partially formed envelopes (one pair is shown by items 502 and504 and another pair is shown by items 506 and 508). Those ordinaryskilled in the art would understand that the sheet could include threepairs, four pairs, five pairs, etc., of envelopes, again depending uponthe size of the envelopes and the size of the sheet 500.

As shown in FIG. 7, this disclosure also presents apparatus embodiments(system 700) that include a media supply 702 that maintains the mediasheets 200, 500, etc. and a printing device 704 that places markings onthe sheets. Again, such markings have opposite orientations on theopposing envelopes of the sheets. The apparatus also includes aseparator 706 (cutter or dicer) that separates the opposing partiallyformed envelopes after the printing device 704 places the marking, toleave partially formed individual envelopes. The separator 706 dividesthe media sheets along the separating line. All such items shown in FIG.7 are well-know as illustrated by the patents incorporated elsewhereherein, and the details of each device is not discussed herein; however,the use of the sheets 200, 500 with such components was not knownpreviously.

A folding device (folder 708) folds the partially formed individualenvelopes to produce the completed individual envelopes. The folderdevice 708 folds the panel 304 of the partially formed individualenvelopes toward the center of the partially formed individual envelopesto put the envelopes in final form (completed individual envelopes).

A roller nip based sheet feeding system 710 provides a sheet pathbetween the media supply 702, the printing device 704, the separator706, and the folder 708. Again, the sheet feeding system 710 has nipspacing larger than the size (height) of the individual envelopes. Forexample, the height of one of the individual envelopes 302 is shown bythe height measure H shown in FIG. 4. As shown in FIG. 7, this heightmeasure H of the individual envelopes is smaller than the spacing Sbetween two of the nips of the sheet feeding system 710, which preventsthe individual envelopes from being utilized with the printing device704. While the printing device 704 could be redesigned to include nipsthat are spaced closer together, such changes are very expensive. Inorder to address these issues, the embodiments herein use the opposingpartially formed envelope media sheets 200, 500, etc. that are discussedabove.

In addition, the printing engine 704 can include some form of processor712 (central processing unit (CPU)) or other computerized device thatcan include a computer storage medium. Computerized devices that includechip-based central processing units (CPU's), input/output devices(including graphic user interfaces (GUI), memories, comparators,processors, etc. are well-known and readily available devices producedby manufacturers such as International Business Machines Corporation,Armonk N.Y., USA and Apple Computer Co., Cupertino Calif., USA. Suchcomputerized devices commonly include input/output devices, powersupplies, processors, electronic storage memories, wiring, etc., thedetails of which are omitted herefrom to allow the reader to focus onthe salient aspects of the embodiments described herein. One feature ofembodiments herein is that the processor 712 can automatically orientthe printing as shown in FIG. 6. Therefore, with embodiments herein, theuser only needs to supply the information that is to be printed on theenvelope (mailing address, return address, postage, other remarks anddata, etc.). The processor can recognize that the envelope media sheets200, 500, etc. are being utilized and can automatically orient theprinting as shown in FIG. 6, as discussed above, utilizing any macro orsimilar series of processing commands or steps (utilizing, for example,if-then statements). Thus, the orienting of the printed items shown inFIG. 6 is performed automatically and without additional a userintervention, which makes the embodiments herein seamless and easy touse.

Therefore, as shown above, the present embodiments provide a system andmethod that, in one example, utilizes a sheet that has a “doubleenvelope” which is intended to be die cut and folded to produce pairs ofindividual envelopes (each having the same dimensions as a standard #10envelope). With embodiments herein, the two envelopes are joinedtogether along the top edge of the envelope flap. Before being separatedfrom one another, the pairs of envelopes are mirror images of eachother. Therefore, the printing process prints addresses and/or otherinformation in a proper orientation for each individual envelope (thatare upside down with respect to one another) since the envelopes faceopposite each other. After printing, the envelopes are separated (diecut) to leave two separate envelopes.

Thus, the embodiments herein can, for example, provide an approximately11″ long double envelope sheet which is easily fed, transported, andstacked in a standard production paper path. The width of the envelopeis the same as a standard #10 envelope at 9.5″. Therefore, theembodiments herein can be used in machines that have paper trays, nipspacing, stacking trays, etc. that are currently designed to accommodatecommon paper sizes, such as A3; A4; 8½×11; 8½×14; etc.

The word “printer” or “image output terminal” as used herein encompassesany apparatus, such as a digital copier, bookmaking machine, facsimilemachine, multi-function machine, etc. which performs a print outputtingfunction for any purpose. The details of printers, printing engines,etc. are well-known by those ordinarily skilled in the art and arediscussed in, for example, U.S. Pat. No. 6,032,004, the completedisclosure of which is fully incorporated herein by reference. Theembodiments herein can encompass embodiments that print in color,monochrome, or handle color or monochrome image data. All foregoingembodiments are specifically applicable to electrostatographic and/orxerographic machines and/or processes.

It will be appreciated that the above-disclosed and other features andfunctions, or alternatives thereof, may be desirably combined into manyother different systems or applications. Various presently unforeseen orunanticipated alternatives, modifications, variations, or improvementstherein may be subsequently made by those skilled in the art which arealso intended to be encompassed by the following claims. The claims canencompass embodiments in hardware, software, and/or a combinationthereof. Unless specifically defined in a specific claim itself, stepsor components of the invention should not be implied or imported fromany above example as limitations to any particular order, number,position, size, shape, angle, color, or material.

1. An apparatus comprising: a media supply maintaining media sheets,said media sheets comprising multiple opposing partially formedenvelopes; a printing engine placing markings on said sheets of saidopposing partially formed envelopes, said markings having oppositeorientations on opposing envelopes of said opposing partially formedenvelopes; a separator that separates said opposing partially formedenvelopes after said printing engine places said marking to leavepartially formed individual envelopes; and a folder that folds saidpartially formed individual envelopes to produce completed individualenvelopes.
 2. The apparatus according to claim 1, said media sheetscomprising a separating line between pairs of said opposing partiallyformed envelopes.
 3. The apparatus according to claim 2, said separatordividing said media sheets along said separating line.
 4. The apparatusaccording to claim 2, said folder folds a panel of said partially formedindividual envelopes bordering said separating line toward a center ofsaid partially formed individual envelopes.
 5. The apparatus accordingto claim 1, said opposite orientations comprise a first orientation anda second orientation upside down with respect to said first orientation.6. An apparatus comprising: a media supply maintaining media sheets,said media sheets comprising pairs of opposing partially formedenvelopes; a printing engine placing markings on said sheets of saidopposing partially formed envelopes, said markings having oppositeorientations on opposing envelopes of said opposing partially formedenvelopes; a separator that separates said opposing partially formedenvelopes after said printing engine places said marking to leavepartially formed individual envelopes; and a folder that folds saidpartially formed individual envelopes to produce completed individualenvelopes; and a roller nip based sheet feeding system providing a sheetpath between said media supply, said printing engine, said separator,and said folder, said sheet feeding system having nip spacing largerthan a size of said individual envelopes.
 7. The apparatus according toclaim 6, said media sheets comprising a separating line between pairs ofsaid opposing partially formed envelopes.
 8. The apparatus according toclaim 7, said separator dividing said media sheets along said separatingline.
 9. The apparatus according to claim 7, said folder folds a panelof said partially formed individual envelopes bordering said separatingline toward a center of said partially formed individual envelopes. 10.The apparatus according to claim 6, said printing engine comprising oneof a electrostatographic and xerographic printing device.
 11. A methodcomprising: supplying media sheets comprising multiple opposingpartially formed envelopes; placing markings on said sheets of saidopposing partially formed envelopes, said markings having oppositeorientations on opposing envelopes of said opposing partially formedenvelopes; separating said opposing partially formed envelopes aftersaid printing engine places said marking to leave partially formedindividual envelopes; and folding said partially formed individualenvelopes to produce completed individual envelopes.
 12. The methodaccording to claim 11, said media sheets comprising a separating linebetween pairs of said opposing partially formed envelopes.
 13. Themethod according to claim 12, said separating comprising dividing saidmedia sheets along said separating line.
 14. The method according toclaim 12, said folding comprising folding a panel of said partiallyformed individual envelopes bordering said separating line toward acenter of said partially formed individual envelopes.
 15. The methodaccording to claim 11, said opposite orientations comprise a firstorientation and a second orientation upside down with respect to saidfirst orientation.
 16. A method comprising: supplying media sheetscomprising multiple opposing partially formed envelopes using a rollernip based sheet feeding system; placing markings on said sheets of saidopposing partially formed envelopes, said markings having oppositeorientations on opposing envelopes of said opposing partially formedenvelopes; separating said opposing partially formed envelopes aftersaid printing engine places said marking to leave partially formedindividual envelopes; and folding said partially formed individualenvelopes to produce completed individual envelopes said sheet feedingsystem having nip spacing larger than a size of said individualenvelopes.
 17. The method according to claim 16, said media sheetscomprising a separating line between pairs of said opposing partiallyformed envelopes.
 18. The method according to claim 17, said separatingcomprising dividing said media sheets along said separating line. 19.The method according to claim 17, said folding comprising folding apanel of said partially formed individual envelopes bordering saidseparating line toward a center of said partially formed individualenvelopes.
 20. The method according to claim 16, said oppositeorientations comprise a first orientation and a second orientationupside down with respect to said first orientation.